Handling system catalogue

Company profile

THE PHILOSOPHY Giovenzana’ s philosophy is based upon the basic principles of business management, dynamism and continuous research into the operator’ s needs in the field of man-machine interaction. These principles, thanks to the experience and professionalism of its staff, guarantees Giovenzana’s development and growth.

THE PRODUCTSGiovenzana, leader in the industrial technology field, is the first choice for:� Handling equipment� Automation� Lifting equipment� Maintenance� Command and control of moving partsDevelopment, design and production are combined to reach a common goal and cover most industrial applications.

QUALITY AS A WAY OF LIFEThe commercial success of a product does not happened by chance, but is the end result of the combined efforts of all human resources operating within an organizational structure that is devoted to quality.Giovenzana is an UNI EN ISO 9001:2008 certified company. Today, Giovenzana’sgoal is not just “to manufacture a quality product”, but also to ensure the protection of our cycle processes Giovenzana’ s company is certificated UNI EN ISO 140001:2004

THE HISTORYWith over 60 years experience in this field, coupled with excellent managerial skills, Giovenzana has maintained growth relying upon:� Market research� Product placement� Manufacturing technology, and above all, team work

The Production

THE PRODUCTION The solutions offered by Giovenzana result from the company’s extensive knowledge of the requirements of industrial electrical accessories, and are in line with all relevant international standards.The solutions fall into three main sectors:

AUTOMATIONAutomation includes Phoenix cam switches from 12 to 630 A and Regolus switch disconnectors from 25 to 160 A; Pegasus control auxiliaries with screw or spring cage terminal contacts blocks; limit switches with safety switches and either die cast or moulded casing; foot switches and micro switches.

LIFTThroughout the years, continuous technological research and development has made Giovenzana the undisputed leader in its field.The range includes: pit bottom push button stations, recall drive control units and inspection boxes.

HANDLING SYSTEMLifting equipment comprises of single and double row pendant stations up to 14 gang for control and direct switching, position and rotary gear limit switches, slip rings, warning horns, busbar conductor rails and festoon system.

�

�

YOUARE

HERE

Lifting equipment: Pendant stations for small hoist application, in single / double row or direct power circuits switchings and tail lift controls .

Limit switches:Rotary gear limit swicthes and control position limit switches

Slip ring:20 A Slip ring from 3 up to 15 rings with IP51 protection case

Warning horn:Single tone, Ø 75mm or 100 mm, available in AC 24/48/110/230 V and in DC 24/48 V

Energy and data transmission:The busbar system TR60 - TR85 series conductor rail range available in pre-mounted conductors (blue line) and continuous conductors (yellow line).The festoon system includes c-rail cable trolley line 30, 41; Wire rope cable trolleys; I-beam light series and heavy series cable trolley.

Conductors:PVC flat cables and round cables with dual strain relief steel rope

Complementary products:Switch disconnectors

Page 43

Page 11

Page 43

Page 26

Page 82

Page 80

Page 44

1 3

54

2

4

6

5 6

7 8

9

10Mounting example:

Mounting example:

Mounting example:

Mounting example:

Mounting example:

Mounting example:

Mounting example:

Catalogue contents

11

Rolling shutter door

Catalogue contents

Picture shows a typical overhead crane assembly

Other product applications:

Slip ring motor

Energy transmission

� Window cleaning

� BMU cradle

10

1

3

1

1

2

8

9

7

4

5

6

111 3 2 9

Hoist

10

TR60 TR85

Product Overview

Line

Picture

Page

P02 P03 HP03

Characteristics

FGR1 FGR2 FGR3

pendant stationProduct type pendant station pendant station

Line

Picture

Page

Characteristics

rotary gear limit switchProduct type rotary gear limit switch rotary gear limit switch

Line

Picture

Page

Characteristics

busbar energy transmissionProduct type busbar energy transmission

12 12 12-25 (safety NC contact)

28 30 32

52 54

shock proof - heat resistanttwo direction interlocked

IP65 double insulationindelible laser engraved symbols

self extinguishing housing/coverratio 012-033-050-075-100-150-200-400

IP65flanged fixing /rear shaft version

potentiometer available

aluminium housing/self ext. coverratio 012-033-050-100-200

IP65flanged fixing /rear shaft version

self extinguishing housing/coverRatio from 1:8 to 1:460

IP66rear shaft version vaible

encoder or potentiometer available

height 60 mm – 40, 60 Apre-mounted conductors (blue line)conductors to be pulled (yellow line)

easy and fast installationcomplies with the relevant international standards

height 85 mm – 40, 70, 100, 140, 200 Apre-mounted conductors (blue line)

conductors to pulled (yellow line)easy and fast installation

complies with the relevant international standards





ergonomic design

PL PLB TLPDC30

G75/100Line 30/41 Wire-Rope I-Beam

Product Overview

pendant station pendant station fixed/pendant station

position limit switch position limit switch position limit switch

pendant station

slip ring

warning hornfestoon energy transmission festoon energy transmission festoon energy transmission



from 5 to 12 holes



from 4 to 14 holes



compact and modern design

self extinguishing housing/coverIthe 20 A cam switch

IP65 double insulationrubber covering wheel

fully adjustable metallic rod


IP65reinforced mechanical stop

close PVC frame IP51modularity from 3 up to 15 rings

80mm diameter ringsrated operating current 20 A

rated insulation voltage Ui 690 V



high power contact block 25 A


IP65for single or double speed motorfully adjustable aluminium rods

trolley load capacity 8 kgwith one or two roller/s

light series trolley load capacity:50 kg – IPE-IPN 80, 100 beam

heavy series trolley load capacity:200 kg – IPE-IPN 80, 100, 120 beam

G75: 50 Hz / G100: 300 to 350 HzG75: 88dB / G100: 93.5 dB

G75 IP30 / G100 IP65**double insulation

metallic “C” rail barLine30: load capacity 100 kg/mLine 41 : load capacity 140 kg/m

steel or plastic trolleyball bearing trolley

14 15 16

40 41 42

12

38

76 77 4368

FCR FFH FCP SCUDO

Certifications

QUALITYGiovenzana, leader in the elevator and lifting equipment field, has gained a prominent position in the automation sector with its launch of industrial control accessories into the market. For many years, all commercial and industrial operations have been integrated within the framework of the UNI EN ISO 9001:2008. Quality system CSQ certificate N 9105. GIOV:Giovenzana has fulfilled its commitment to the quality of its products since 1995. The quality system is the end user’s guarantee that all production stages are maintained under strict control and adhere to the requirements set by the company, both in terms of customer expectations and compliance to the relevant international standards as proved by the various certificates Giovenzana holds for its products. With the certification UNI EN ISO 14001:2004, Giovenzana keeps up with new technologies in order to reduce the consumption of raw materials, energy and natural resources and to minimize refuse and emissions in hopes of progressively reducing negative impacts on the environment.Giovenzana products are in conformity to directives Rohs, Pfos, Raee and Reach.The certification CSQ N 9191. GIBV

COMPLIANCEAll Giovenzana products are manufactured according to the relevant Cee directives. Giovenzana certifies this compliance with a declaration of conformity.

CERTIFICATIONSIn order to reach the high level of quality Giovenzana’s products achieve, they are tested by multiple third parties. In order to obtain the UL mark, Giovenzana submits its products to be tested by Underwriter Laboratories Inc., one of the mostprestigious independent certification companies in the world.

CEE DIRECTIVESAs of January 1, 1997 it is compulsory to CE mark allelectro-mechanical products. This has been outlined by two important regulations:72/23 CEE and 93/68 CEE Low Voltage Directives.

CE MARKEuropean directives, applied to all national regulations, set the minimum requirements in term of safety of all electrical material sold within the EU. The compliance to these requirements is certified to the manufacturer by the CE mark placed on the products.

STANDARDSGiovenzana’s products comply with both the European EN and the American UL standards. These regulations, such as the EN 60024 (covering the safety requirements of the electrical circuits on board industrial machinery), define the characteristics, performance and use of the products.

EN EUROPEAN STANDARDSThe EN European standards usually originate from IEC International and are the result of the collaboration between CENELEC (European Committee for Electrotechnical Standardization) member countries. These standards cover and eliminate existing national standards that may be contradictory or out of date.

11

Lifting equipment Contents

LIF

TIN

G E

QU

IPM

EN

T

Pendant stations for small hoist application, in single / double row or direct power circuits

switchings and tail lift controls. page 12 to 25

Giovenzana International Company, leader in lifting equipment control, makes a wide range of standard products for all installation requirements, and all biult to high quality specification and safety guidelines.The Lift Equipment products series comply with: IEC 947-5-1, EN60947-5-1, UL508 and use: IEC 204-1, EN60204-1, EN ISO 13850, all achieved according to the needs and requirements of Cee 89/392.All operators are coloured and the laser-engraved, indelible legends comply with EN60204-1 and FEM 9.941.CERTIFICATIONS: The pendant stations P02, P03 , HP03, PL series can be certificated cUL.

Use (recommended) Line Picture Characteristic

P02Two push button pendant stations for small hoist :• single speed or two speed motor• direct motor control 1kW – 1speed• available in UL/CSA requirements

page 12 (item available in kit-form,: enclosure, contact block and operator available separately for customization)

P03Three push button pendant stations for small hoist:• single speed motor or two speed motor• direct motor control 1kW – 1speed• available in UL/CSA requirements


HP03

Ergonomic pendant stations for small hoist :• single speed motor• two speed motor• available in UL/CSA requirements• safety line available page 25


DC30Pendant stations for high power hoist:• direct motor control single phase and three phase• Ith 25A - 1phase/2poles 230…400V 2.2kW

3phase/3poles 230…400V 4kW

page 12

PLSINGLE-row pendant stations for crane control circuits:• single speed motor or two-speed motor• available in different configuration with 5-7-8-10-12 holes• available in UL/CSA requirements


PLBDOUBLE-row pendant stations for crane control circuits:• single speed motor• two speed motor• available in different configuration with 4-6-8-10-12-14 holes


TLP Compact pendant stations for lifting platform and tails lift application (pendant or wall fixing)


High power!

Ergonomic!

design

Compact!

design

� Hoist

� Overhead crane

� Lifting platform

�Truck tails lift

12

230

LAYOUT CONFIGURATION

250

250

TWO SPEED

SINGLE SPEED(* TILTING BUTTON16A – 250Vac ½ HP)

SINGLE SPEED

230

250

230

(*) HIGH POWER CONTACTSDIRECT MOTOR CONTROL

1Kw 1ph

460

450

460SINGLE SPEED

TWO SPEED 460

PICTURE

330SINGLE SPEED

TWO SPEED 350

600

600

600

SINGLE SPEED

CODE

P02.1

P02.2

P02.4

P02.CD

P02.RM

P02.D2

P03CD

P03.2

P03.3

P03D2

HP03.D2

HP03

DC30

DC30.GE

DC30D2 650

CONTACT TYPE

TWO SPEED

3 NO1 NC

3 NO1 NC

2 NO2 NC

2 NO2 NC

(*) Ith 25A EXTRA HIGH POWERCONTACTS BLOCK FOR

DIRECT MOTOR CONTROL :2.2kW 1ph / 4kW 3ph

(*) Ith 25A EXTRA HIGH POWERCONTACTS BLOCK FOR

DIRECT MOTOR CONTROL :2.2kW 1ph / 4kW 3ph

(*) HIGH POWER CONTACTSDIRECT MOTOR CONTROL

1Kw 1ph

3 NO1 NC

3 NO1 NC (*)

4 NO 4 NO (*)

(*)

(*)

P02

P03

HP03

DC30

Pendant stations Hoist control: P02 P03 HP03 DC30

1 NO* 1 NO*

I^

II^

440P03.1

I^

II^

I^

II^

(*) (*)

(*) (*)

(*) (*)

(*) (*)

(*) (*)

(*) (*)

(*)

(*)

(*)

LIF

TIN

G E

QU

IPM

EN

T

Characteristics:

� Bi-directional, mechanically interlocked� IP 65 double insulation IEC/EN60529� General and electrical data page 23� Laser engraved symbols comply with EN60204-1, FEM 9.941� Shock proof and heat resistant

WEIGHT[gr]

DC30.RG

13

P02

P03

HP03

DC30

Pendant stations Dimensions: P02 P03 HP03 DC30

LIF

TIN

G E

QU

IPM

EN

T

14

560

620

590

740

830

860

890

920

990

1.14

0

Pendant Stationsw

eigh

t[g

r.]

CO

DE

LAYO

UT

770

800

830

DIM

ENSI

ON

S

5 55 7 7 8 8 8 10 127 7 8

N°p

ush

butt

oncranes control circuits: PL

345

345

345

495

495

530

530

530

640

710L

leng

ht[m

m]

495

495

530

LIF

TIN

G E

QU

IPM

EN

T

NC NO NO

(*) two speedcontact block

NO

NO

NO

NO NO NO

NO NO

NO

PUSH BUTTON TYPE – CONTACT TYPE COUPLED

Characteristics:

� Bi-directional, mechanically interlocked� IP 65 double insulation IEC/EN60529� General and electrical data page 23� Laser engraved symbols comply with EN60204-1, FEM 9.941� Shock proof and heat resistant� Available in UL/CSA requirements

NO

15

560

620

590

830

860

890

920

990

1.14

0

wei

ght

[gr.

]C

OD

ELA

YOU

T

770

800

830

4 64 6 8 8 8 10 12 146 8

N°p

ush

butt

onD

IMEN

SIO

NS

345

399

345

453

453

453

547

604

655

399

399

453L

leng

ht[m

m]

Pendant Stations cranes control circuits: PLB

LIF

TIN

G E

QU

IPM

EN

T

Characteristics:

� Bi-directional, mechanically interlocked� IP 65 double insulation IEC/EN60529� General and electrical data page 23� Laser engraved symbols comply with EN60204-1, FEM 9.941� Shock proof and heat resistant

NC NO NO

(*) two speedcontact block

NO

NO

NO

NO NO NO

NO NO

NO

TIPO DI PULSANTE – TIPO DI CONTATTO ABBINATO

NO

NO

MOBILE-PENDANT FIXING (with WALL BRACKET accessories)

16

wei

ght

[gr.

]C

OD

ELA

YOU

TN

°pus

hbu

tton

DIM

ENSI

ON

S

120

1

80

200

2

115

120

1

80

314

4

185

255

3

150

255

3

150

314

4

185L

leng

ht[m

m]

LIF

TIN

G E

QU

IPM

EN

T

Lifting platform – Truck tail lift: TLPPendant / Fixed Stations

push pull twist release

selector switch

NC NO NO

PUSH BUTTON TYPE CONTACT TYPE COUPLED

NO

L

WithEmergency Stop

WithSelector Switch

WALL FIXING

Characteristics:

� Compact and modern design� Bi-directional, mechanically interlocked� IP 65 double insulation IEC/EN60529� General and electrical data page 23� Laser engraved symbols comply with EN60204-1, FEM 9.941� Contact block with spring cage terminal� Shock proof and heat resistant� Mobile-Pendant (with wall bracket accessories) or wall fixed mounting

selector switch

Pendant / Fixed Stations

17

Contact Block type: PL004 - PCW

LIF

TIN

G E

QU

IPM

EN

T

SimplyContact

Point

P02

PL004 lineDC30

(e-stop only)P03 PLBPL

NC

PL004001

N0

PL004002

Clamping screw M3.5 terminal with mobile “bent tile” plate that works with cables of different section

Dimensions

HP03

PCW lineTLP

MarkingsThreeContact Point

safe & durableenergy transmission

NC

PCW01

N0

PCW10

Spring cage terminal with two separated platesthat works with cables with different section

Code: PCW01FT (see page 24)

An important step in accident prevention!

Safety contact block

Dimensions

1) Insert the screwdriver2) turn 1/4 the screwdriver3) insert wire 4) remove the screwdriver

Spring cage terminal:

Markings

Technical data see page 23

18

Pendant / Fixed Stations KIT To be customizedCreate your customized station in 4 steps

CODE

WEIGHT[gr]

HOLESn°

2

3

5

7

8

10

12

4

6

8

10

12

14

1

2

3

4

700

710

810

910

800

STEP 1Choose station

type

LIF

TIN

G E

QU

IPM

EN

T

SMALL DIMENSIONS BIG

P02

P03

PL

PLB

TLP

P02K

P03K

PL05K

PL07K

PL08K

PL10K

PL12K

PLB04K

PLB06K

PLB08K

PLB10K

PLB12K

PLB14K

TLP1K

TLP2K

TLP3K

TLP4K

180

258

410

540

600

410

510

610

100

130

160

200

19

Pendant / Fixed Stations

P02-P03-PL-PLB

NC NO NC NO

TLP

STEP 2Choose OPERATOR

NOT for TLP

KIT To be customizedCreate your customized station in 4 steps

(*) Symbols according to FEM 9.941Customized engraving available (min. quantity applies)

(*)

colore?

(*)

LIF

TIN

G E

QU

IPM

EN

T

STEP 3Choose CONTACT TYPE

20


LIF

TIN

G E

QU

IPM

EN

T

TLPP03

P02

STEP 4Mounting

instructions

21


LIF

TIN

G E

QU

IPM

EN

T

1° sp. 2° sp.

PL

PLB

2° speed“low” plunger

1° speed“high” plunger

22

Pendant / Fixed Stations Spare Parts / Accessories

SPARE PARTS:

NOT for TLPNOT for TLP

P02 – P03 – PL – PLB – TLP

� Operators and contacts block codes please go to page 19

TLP ACCESSORIES

LIF

TIN

G E

QU

IPM

EN

T

DC30

mechanical interlock

1…3

416000061

1600006212901054

WALL BRACKET SPIRAL CABLE GLAND

DRAWINGS EXAMPLES

CONTACT BLOCKS RUBBER BUTTON COVER

Pendant / Fixed Stations General and Electrical data

LIF

TIN

G E

QU

IPM

EN

T

23

Electrical characteristicscontact blocks

P02 – P03 – HP03 – PL – PLB – TLP DC30

Markings

Rated insulation voltage [Ui] 690V 500V

Rated thermal current [Ith] 16A 25A

Rated impulse withstand voltage [Uimp] 4kV 4kV

Frequency 50Hz – 50/60 Hz type PCW (HP03-TLP) 50Hz

Rated operating current [Ie]

AC-15alternate current

(V) 24 60 110 240 400 440 500 690

type: PL004..P02/P03/DC30 e-stop/PL/PLB

(A) 16 12 8 6 4 3.5 3 1 -

type: PCW..HP03-TLP

(A) 10 8 6 5 4 4 4 2 -

DC-13direct

current

(V) 24 48 60 110 220 250


(A) 2 1.2 0.85 0.4 0.25 - -

type: PCW..HP03-TLP

(A) 2 2 1 0.4 - 0.4 -

AC-3alternatecurrent

1phase-2poles 230V-400V - 2.2kW

3phase-3poles 230V-400V - 3kW

Conditional short circuit withstand current 1000A 1000A

Fuse rating gG 10A - 500V aM 12A - 500V

Contact insulation resistance ≤ 25mΩ -

Switchingmechanism


slow break double gap contactssingle pad slow break double gap contacts

single padtype: PCW..HP03-TLP

slow break double gap contactsthree pads

Positive operation NC contact block -

Terminal type


M3.5 screwM3.5 screw

type: PCW..HP03-TLP

spring cage terminal

Terminalcapactity


No. 1 or 2 flexible and solid conductor min 1 max 2.5 mm2

No. 1 or 2 flexible and solid conductor min 1 max 2.5 mm2type: PCW..

HP03-TLPNo. 1 or 2 flexible and solid conductor min 0.5 max 2.5 mm2

UL508 characteristics

General use 600V ac 16A -

Designation code (HD) Heavy Duty A600-Q600 -

General characteristics P02 – P03 – HP03 – PL – PLB – TLP DC30

In conformity to standards IEC / EN60947-5-1 IEC / EN60947-3

MaterialP02 P03 HP03 PL PLB TLP

ABSPP ABS ABS ABS ABS PP

Material group II II

Pollution class 3 3

Climatetemperature

operating -25°C + 70°C -25°C + 70°C

storage -30°C + 70°C -30°C + 70°C

Climate resistanceIEC68 part 2-3 hot damp hot damp

IEC68 part 2-30 unsettled hot damp unsettled hot damp

Cable entry� P02 – P03: rubber cable sleeve Ø7…18mm� PL – PLB: rubber cable sleeve Ø9…24mm� HP03 – TLP: cable gland M20

cable gland M25

Note: P02 – P03 – HP03 – PL line available in UL/CSA requirements

24

Pendant / Fixed Stations Safety Line

LIF

TIN

G E

QU

IPM

EN

T

OPERATING SYSTEM

CONTACT MOUNTED

E-STOPNOT PUSHED

CONTACT MOUNTED

E-STOPPUSHED

CONTACT OPEN

CONTACTSEPARATED

(bad assembly or mechanical break )

CONTACT OPEN

Safety contact block

Code: PCW01FT(Family line PCW: spring cage terminal – see page 17)

An important step in accident prevention!

Giovenzana International B.V. has developed a new technology in the field of industrial and lift automation.The product is designed to maximize the performance of the NC mushroom e-stop contact which results in a risk factor of zero.The NC contact will open in the event of accidental release of the contact block from the base.In the unlikely event of mechanical failure or support breaking, the contact block is designed to intervene and open the circuit. This will block any further operation of the machine.This is an important step ahead in accident prevention and emergency device intervention.See following sequence with possible operating conditions.

Detached contact due to a bad assembly or mechanical failure:

difference between a normal NC Vs a Safety NC contact:

OK

Normal NC – PCW01 Safety NC – PCW01FT E-stop

Activated

DANGER!:

NO response from the NC contactIf separated from the operator the safey

NC contact block switch in NO

E-stopActivated

3 4

3 4

3 4

CONTACT CLOSED

25

Pendant / Fixed Stations Safety Line

NOTE: available in UL/CSA requirements

LIF

TIN

G E

QU

IPM

EN

T

Stackingforbidden!Do not fix the safety

contact block under a contact block

SINGLE SPEED

CONTACT TYPE

HP03

WEIGHT[gr]LAYOUT CONFIGURATIONPICTURE CODE

330HP03.SS

ThreeContact Point

safe & durableenergy trasmission

Dimensions

1) Insert the screwdriver2) turn 1/4 the screwdriver3) insert wire 4) remove the screwdriver

Spring cage terminal:Markings

Pendant Stations with PCW01FT - Characteristics:

� Shock proof and heat resistant� Bi-directional, mechanically interlocked� IP 65 double insulation IEC/EN60529� General and electrical data page 23� Laser engraved symbols comply with EN60204-1, FEM 9.941

26

Limit switches Rotary Gear – product description

LIM

IT S

WIT

CH

ES

Rotary Gear Limit switches page 26 to 35

The Giovenzana’s rotary gear limit switch is a device used to control the number of rotation or direction angle of industrial and building machines. A typical application is controlling the position of the rolling shutter door or overhead cranes etc… . The unit, through a gear system and cams transmission, controls 2, 4 or more microswitches so that after a definied number of revolutions, it can prepare the motor or the device to start or stop running. The microswitches have a calibration screw that operates independently on each cam; so it can calibrate the opening and closing of each micro according the functional requirements needed.The gear-based transmission system allows you to choose different ratios.It can also be supplied with rear shaft version or complete of linear detector (potentiometer or encoder) too.

Picture shows a FGR1/2/3 working on a crane system Picture shows a FGR1/2/3 working on a rolling shutter door

Ratio

The Giovenana’s rotarygear limit switch are available in differenttransmission ratio. The ratio is the differencebetween the number ofrotation of the main shaftand the number of rotation of the cams.

20 rpm

Ratio gear

050

1000 rpm

Potentiometer & Encoder

In addition to the microswitch :� FGR1 line: available withpotentiometer(direct ratio 1:1)� FGR3 line : available withpotentiometer or encoderhaving:direct ratio 1:1 or ratio 1:X(X=cam block ratio)

Potentiometer

in FGR1

27

Limit switches Rotary Gear - table of contents

LIM

IT S

WIT

CH

ES

Characteristics

Case self extinguishing housing V0 UL94aluminium housing

self extinguishing cover V0 UL94 self extinguishing housing V0 UL94

Main / cam shaftratio

012-033-050-075-100-150-200-400 012-033-050-100-200 1:8 to 1:460

Protection class IP65 IP65 IP66

Shaft type- steel

- coaxial shaft version available- steel mounted on ball bearing- coaxial shaft version available

- AISI 304 stainless steel mounted on ball bearing

- coaxial shaft version available

Fixing type- bottom

- front (flanged version)- bottom

- front with FLG accessoriesbottom

(different metal plate available)

Microswitch

8A – 250V – silver platedIEC/EN61058-1 / UL1054

1NC-1NO changeover fast triggerpositive opening

markings

8A - 250V – silver platedIEC/EN61058-1 / UL1054


markings

8A – 250V – silver platedIEC/EN61058-1 / UL1054


markings

Microswitchmax n° / notes

max 4 - micrometric adjustmentwheel drive control (long life)

max 6 - micrometric adjustmentmax 4 - micrometric adjustment

wheel drive control (long life)

Cam blockself-lubricating with transparentsupport for easier cam viewing

self-lubricating with transparentsupport for easier cam viewing

self-lubricating with transparentsupport for easier cam viewing

Cable entry M20 or M16 (max 4) M20 (max 2) M20 (max 3)

Options- N° 5 different cam shapes

- potentiometer (direct ratio 1:1)N° 3 different cam shapes

- N° 5 different cam shapes- potentiometer or encoder

(direct ratio 1:1 or 1:X)

Line FGR1 FGR2 FGR3Page 28 30 32

Picture

X-ray view

28

Limit switches Rotary Gear – FGR1

LIM

IT S

WIT

CH

ES

Characteristics

Case self extinguishing housing V0 UL94

Ratio 012-033-050-075-100-150-200-400

Protectionclass

IP65

Shaft type- steel


Fixing type- bottom

- front (flanged version)

Microswitch

8A – 250V – silver plated contactsIEC/EN61058-1 / UL1054

1NC-1NO changeover fast triggerself cleaning positive opening

markings


max 4 - micrometric adjustmentroller lever control (long life)


Cable entry M20 or M16 (max 4)

Options(see page 34)

- 5 different cam shapes / 15 pinions- potentiometer (3 support version)

Ratio Base Fixing Flanged FixingN° of microswitches

2-3-4Potentiometer2 .5 / 5 / 1 0 k Ω

Rear shaftMicroswitch

cams

012 FGR100124 FGR100124F 4 silver plated

NO NO STANDARD


NO NO STANDARD


NO NO STANDARD


NO NO STANDARD


NO NO STANDARD


NO NO STANDARD


NO NO STANDARD


NO NO STANDARD

Version and options available

� Base Fixing � Flanged Fixing

� Rear shaft � With potentiometer

Standard A (10°)B (60°)C (180°)E (10 tips) D (opposite)

See page 34

for complete

specifications

roller lever control (long life)

29


LIM

IT S

WIT

CH

ES

Fixing holes

Base fixing

Flangedfixing

Dimensions

� rear shaft version

Microswitch system calibration guide

I. Loosenthe main screw (1)

II. Adjust the screws (2)

III. Tighternthe main screw (1)

Microswitch table activation (with the standard cam”A”)

1

2

transparentcover

Spare parts

Microswitch MFI.3

1

4

2

OpenClosed 1

4

2

RatioRevolutions referred to the cam’s activation

A a B b C c D d

12 0.65 11.35 1.3 10.7 1.95 10.05 2.6 9.4

33 1.75 31.25 3.5 29.5 5.25 27.75 7 26

50 2.75 47.25 5.5 44.5 8.25 41.75 11 39

75 3.75 71.5 7.5 67.5 11.25 63.75 15 60

100 4.75 95.25 9.5 90.5 14.25 85.75 19 81

150 7.5 142.5 15 135 22.5 127.5 30 120

200 10.5 189.5 21 179 31.5 168.5 42 158

400 21 379 42 358 63 337 84 316

NOTE:The movement refers tothe action of the camon contact 1-2 (NC).The microswitch haveall changeover contacts.

30


LIM

IT S

WIT

CH

ES

Characteristics

Case- aluminium housing

- self extinguishing cover V0 UL94

Ratio 012-033-050-100-200

Protectionclass

IP65

Shaft type- steel mounted on ball bearing- coaxial shaft version available

Fixing type- bottom

- front (flanged with FLG accessories)

Microswitch


1NC-1NO changeover fast triggerself cleaning positive opening

markings


max 6 - micrometric adjustment


Cable entry M20 (max 4) included


- 3 different cam shapes- 15 pinions

Ratio Sigle shaft Rear shaftMicroswitch

cams


� Base Fixing

� Rear shaft

� Flanged Fixing

(with FLG accessories)

Standard A (30°)B (15°)C (90°)

4microswitches

6microswitches

4microswitches

6microswitches

012 FGR2006 FGR20066 FGR2006B FGR2006B6 STANDARD





See page 34

for complete

specifications

31


Fixing holes

Base fixing

Flangedfixing

(FLG)

Dimensions





Microswitch table activation (with the standard cam”A”)L

IMIT

SW

ITC

HE

S


OpenClosed


1

2

transparentcover

Spare parts / Accessories

Microswitch Flange

MFI FLG1

4

2

1

4

2


A a B b C c D d E e F f

012 1.25 10.75 2.5 9.5 3.75 8.25 5 7 6.25 5.75 7.5 4.5

033 3.5 29.5 7 26 10.5 22.5 14 19 17.5 15.5 21 13

050 5 45 10 40 15 35 20 30 25 25 30 20

100 10 90 20 80 30 70 40 60 50 50 60 40

200 20 180 40 160 60 140 80 120 100 100 120 80

32



� Base Fixing

Characteristics


Ratio 1:8 to 1:460

Protectionclass

IP66

Shaft type- AISI 304 stainless steel mounted on ball bearing


Fixing type- bottom

(different metal plate available)

Microswitch


1NC-1NO changeover fast triggerself cleaning positive opening markings

Max n° ofmicroswitch

max 4 - micrometric adjustmentroller lever control (long life)


Cable entry M20 (max 3)


- 5 different cam shapes / 15 pinions- potentiometer or encoder

(3 support version)direct ratio 1:1 or 1:X(X= cam’s block ratio)

LIM

IT S

WIT

CH

ES

� Rear shaft

� With encoder

Standard A (10°)B (60°)C (180°)E (10 tips) D (opposite)

See page 34

for complete

specifications

FGR3 coding system:

FGR3 0 060 4 1 51 - XX

Line ID Optical reader RatioN° of

microswitch:Shaft type

Piniontype:

Option

0= NO(however the unit permitsthe future equipment)1= Encoder2= Potentiometer

008 to 4602= two4= four

0= single output1= double output

the last twonumbers of the Giovenzana’s code table list on page 32

Suffix: define the code according customer’s specifications like encoder, potentiometer, cams, shaft, etc etc type

Example:

FGR3 1 060 4 1 61

Limit switch FGR3 line with encoder, ratio 1:60 with 4 microswitches, single shaft output and complete of pinion M14-Z10 (code 16020061)

equipped with standard cam type “A” (10°)

33


LIM

IT S

WIT

CH

ES

Fixing holes Dimensions

Microswitch table activation (with the standard cam”A”)

Fare

Spare parts

Microswitch MFI.3

1

4

2






1

2

transparentcover


A a B b C c D d

12 0.65 11.35 1.3 10.7 1.95 10.05 2.6 9.4

33 1.75 31.25 3.5 29.5 5.25 27.75 7 26

50 2.75 47.25 5.5 44.5 8.25 41.75 11 39

75 3.75 71.5 7.5 67.5 11.25 63.75 15 60

100 4.75 95.25 9.5 90.5 14.25 85.75 19 81

150 7.5 142.5 15 135 22.5 127.5 30 120

200 10.5 189.5 21 179 31.5 168.5 42 158

400 21 379 42 358 63 337 84 316

OpenClosed


1

4

2

Cam shapes

FGR1 – FGR3 FGR2

Standard “A” (10°) “B” (60°) “C” (180°) Standard “A” (10°) “B” (15°)

16020081 16020097 16020094 11703015 11703019

“D” (opposite ) “E” (10 tips) “C” (90°)

16020095 16020093 11703013

Limit switches

Note:

�“Water jet cut”with metal flange

o Moulded

LIM

IT S

WIT

CH

ES

Pinion type� PA66 material

16020051 M20 - Z12 �

16020052 M14 – Z17 �

16020053 M22 – Z10 �

16020054 M18 – Z12 �

16020055 M16 – Z13 �

16020056 M10 – Z17 �

16020057 M6 – Z13 �

16020058 M20 – Z8 o

16020059 M16 – Z10 o

16020060 M12 – Z12 o

16020061 M14 – Z10 o

16020062 M12 – Z10 o

16020063 M8 – Z12 o

16020065 M6 – Z11 o

16020066 M5 – Z12 o

FGR1/3: Potentiometer / Encoder support versions

16020015 16020016 16020017

� on request available

other versions

� on request available

other versions

FGR1/2/3: Oldham coupling

FGH

Rotary GearPinions, cams, accessories, supports

34

Max displacement

Drill and pin to the

limit switch’ s shaft

Electrical characteristics FGR1 FGR2 FGR3

Microswitch product IDMFI.3 - Giovenzana line

wheel drive control (long life)MFI - Giovenzana line

MFI.3 - Giovenzana linewheel drive control (long life)

Standards IEC/EN 61058-1, UL 1054 IEC/EN 61058-1, UL 1054 IEC/EN 61058-1, UL 1054

Markings

Rated insulation voltage [Ui] 250V 250V 250V

Rated thermal current [Ith] 8A 8A 8A

Ratedoperating

current

Resistive load 8A - 250Vac 8A - 250Vac 8A - 250Vac

Inductive load 3A - 250Vac 3A - 250Vac 3A - 250Vac

Positive opening contacts

Contact block

function1NC+1NO changeover

fast trigger1NC+1NO changeover

fast trigger1NC+1NO changeover

fast trigger

contact silver plated / self cleaning silver plated / self cleaning silver plated / self cleaning

connections fast-on 0.8x6.3mm fast-on 0.8x6.3mm fast-on 0.8x6.3mm

General characteristics FGR1 FGR2 FGR3

Markings

Case self extinguishing V0 UL94cast aluminium housing

self extinguishing cover V0 UL94 self extinguishing V0 UL94

Ratio012-033-050-075100-150-200-400

012-033-050-100-200 1:8 to 1:460

Protection class IEC/EN 60529 IP65 IP65 IP66

Shaft type steel steel mounted on ball bearingAISI 304 stainless steel

mounted on ball bearing

Fixing type base / flanged base / flanged (FLG accessories) base

Max n° of microswitch 4 6 4

Climatetemperature

Operating -25°C + 70°C -25°C + 70°C -40°C + 90°C

Storage -30°C + 70°C -30°C + 70°C -40°C + 90°C

Cable entry M20 or M16 (max 4) M20 (max 4 included) M20 (max 3)

Microswitch cams self-lubricating self-lubricating self-lubricating

Micrometric adjustment screw zamak material PA material zamak material

Weight KG (approx) 0.75 1.1 1.5

35

Limit switches Rotary Gear – Tecnical Data

LIM

IT S

WIT

CH

ES

Options FGR1 FGR2 FGR3

Rear shaft available available available

Potentiometer 2 . 5 / 5 / 1 0 k Ω (*) - according customer request

Encoder - - according customer request

Cam’s shape / Pinion available 5 / 15 3 / 15 5 / 15

(*) Standard potentiometers: available other versions on request

36

Limit switches Position – product description

LIM

IT S

WIT

CH

ES

Position Limit switches page 36 to 42

The position (rotary-angular) limit switch is used to control several handling system:• sophisticated crane system:

the unit controls power operating system (ex. PLC) and allows the crane to slow-down and/or to stop running.

• hoist:the unit is used to stop the hoist running whenever it reaches a “limit” position

� Different combinations available for all standard system.� Customization available on request.

Picture shows a FCR working on a crane system Picture shows a FCP working on a hoist

How it works?

As an example, an FCR006 is typically used on a sophisticated crane system. Its function is to control the crane as itapproaches operational limits in the following sequence:With the crane moving forward the end position, the FCR006

controls the crane’s speed reducing the speed (first step) thanstopping the crane (second step) .In this position the forward command is no longer enabled.Only the reversing command is enabled for operation, in the first speed than in the second speed. Example FCR006

FORWARD →

1° step reduce the speed

2° step stop the system

← REVERSE

Go in first speed than,

asap the FCR change pos.,

in the second speed

moving device

37

Limit switches

LIM

IT S

WIT

CH

ES

Characteristics

Standards IEC/EN 60947/3 IEC/EN 60947/3 IEC/EN 60947/3, EN81-1

Caseself extinguishing housing

V0 UL94self extinguishing cover

V0 UL94self extinguishing housing

V0 UL94

Protection classIEC/EN 60529

IP65 IP65 IP65

Camswitch

enclosed thermalcurrent [Ithe]

16A 20A 40A

rated insulationvoltage [Ui]

690V 690V 690V

product IDP016

Giovenzana linePX20

Giovenzana lineCX40

Giovenzana line

contactsdouble gap

positive openingdouble gap


positive opening

markings

Cable entry N° 1 dia. 22.5mm 1xM20 + 1xM16 M20 (max 8)

Versions

- single or double speedmotor configuration

- 3,4 or 4 with mechanical stop positions

single speed motor configuration(other configuration on request)

two pole on-off switch(other configuration on request)

Notes

fully adjustable aluminium rods□ 6x300mm

with “0” indicator- reinforced mechanical stop

- fully adjustable metallic rods□ 6x120mm

- reinforced mechanical stop-rubber covering wheel

- reinforced mechanical stop

Line FCR FFH FCPPage 38 40 41

Picture

X-ray view

Position - table of contents

38

Limit switches Position switch – FCR

LIM

IT S

WIT

CH

ES

Picture

Characteristics

Standards IEC/EN 60947/3



IP65(double insulation )

Camswitch


16A


690V

product IDP016

Giovenzana line

contactsdouble gap

positive opening

markings

Cable entry N° 1 dia. 22.5mm

Versions



Notes

fully adjustable aluminium rods□ 6x300mm

with “0” indicator- reinforced mechanical stop

Versions

FCR001 singlespeed

3 positionswith mechanical

interlock (●)

FCR002 singlespeed


interlock (●)

FCR003 singlespeed

4 positionsNO mechanical

interlock

FCR004 singlespeed


interlock

FCR005 singlespeed


interlock

FCR006 twospeeds


interlock (●)

3-4

1-2

Cont

.Po

s. -90° 0

+90°

7-8

5-6

3-4

1-2

Cont

.Po

s. -90° 0

+90°

3-4

1-2

Cont

.Po

s. 0 90°

180°

270°

- empty

5-6

- empty

1-2

Cont

.Po

s. 0 90°

180°

270°

- empty

5-6

- empty

1-2

Cont

.Po

s. 0 90°

180°

270°

7-8

5-6

3-4

1-2

Cont

.Po

s. -180

°-9

0° 0+9

0°+1

80°

X-ray view

Other versions available on request →

contact opencontact close

Reinforced mechanical stop insert

metallic stopinsert

metallic cam’scontrol shaft

39

Limit switches Position switch– FCR

LIM

IT S

WIT

CH

ES

Dimensions

Rods adjusting guide

I. Loosenthe four scews (1)

II. Adjust the rods

III. Tightenthe four screws (1)

1

“ZERO” indicator

Fixing holes Section view

40

Limit switches Position switch – FFH

LIM

IT S

WIT

CH

ES

Picture

Characteristics





Camswitch


20A


690V

product IDPX20

Giovenzana line

contactsdouble gap

positive opening

markings

Cable entry 1xM20 + 1xM16

Versionssingle speed motor configuration(other configuration on request)

Notes

-fully adjustable metallic rods□ 6x120mm


Versions

FFH2C singlespeed

3 positionsautomatic return to “0”

with mechanicalinterlock (●)

FFH2C-1 singlespeed



3-4

1-2

Cont

.Po

s. -65° 0

+65°

3-4

1-2

Cont

.Po

s. -65° 0

+65°

X-ray view

↑ Other versions available on request

Dimensions

Fixing holes

Rod adjusting guide

I. Loosenthe four screws (1)

II. Adjust the rods

III. Tightenthe four screws (1)

Reinforcedmechanicalstop insert

1

Section view


41

Limit switches Position switch – FCP

LIM

IT S

WIT

CH

ES

Picture

Characteristics





Camswitch


40A


690V

product IDCX40

Giovenzana line

contactsdouble gap

positive opening

markings

Cable entry M20 (max 8)

Versionstwo pole on-off switch

(other configuration on request)

Notes - reinforced mechanical stop

Versions

FCP245 singlespeed



3-4

1-2

Cont

.Po

s. -50° 0

+50°

↑ Other versions available on request

Dimensions

Fixing holes

Section view


X-ray view

Reinforced mechanical stop insert

metallic stopinsert

metallic cam’scontrol shaft

General characteristics FCR FFH FCP

Markings

Standards IEC/EN 60947/3 IEC/EN 60947/3 IEC/EN 60947/3

Caseself extinguishing housing



V0 UL94





Climatetemperature

Operating -25°C + 55°C

Storage -30°C + 70°C

Cable entry N° 1 dia. 22.5mm 1xM20 + 1xM16 M20 (max 8)

Versions



single speedmotor configuration

(other configuration on request)

two pole on-off switch(other configuration on request)

Notes

fully adjustable aluminiumrods □ 6x300mmwith “0” indicator


- fully adjustable metallic rods□ 6x120mm



Weight KG (approx) 0.5 0.35 0.55

Limit switches Position switch – Tecnical Data

Electrical characteristics FCR FFH FCP

Cam switch product IDP016

Giovenzana linePX20

Giovenzana lineCX40

Giovenzana line

Standards IEC/EN 60947/3 – UL508 IEC/EN 60947/3 – UL508 IEC/EN 60947/3 – UL508

Markings

Enclosed thermal current [Ithe] 16A 20A 40A

Rated insulation voltage [Ui] 690V 690V 690V

Frequency 50/60 Hz 50/60 Hz 50/60 Hz

Ratedoperating

current

AC21A-AC22A 16A - 690Vac 20A - 690Vac 40A - 690Vac

AC23A 3ph 230V 13A - 4kW 16A - 5kW 35A - 11kW

AC23A 3ph 400V 13A - 7.5kW 16A - 9kW 32A – 18.5kW

Rated short circuit withstandcurrent (gG 20A - 690V)

5kA 5kA 10kA

Contactsdouble gap



positive opening

Connections

caliber A3 (EN60947-1) A3 (EN60947-1) A5 (EN60947-1)

screw size M3.5 M3.5 M4

max torque0.8 Nm (EN60947-1)

7.5 lb.in. (UL508)0.8 Nm (EN60947-1)

7.5 lb.in. (UL508)1.2 Nm (EN60947-1) 10.6 lb.in. (UL508)

Connectablesection

flexible or solidmin/MAX

1x0.75/4 – 2x0.75/2.5 1x0.75/4 – 2x0.75/2.5 2x2.5/10

flexible or solidAWG

16-12 16-12 14-6

LIM

IT S

WIT

CH

ES

42

43

Slip rings / Warning horns

SL

IP R

ING

SW

AR

NIN

G H

OR

NS

Slip rings page 43

Slip rings are used to transfer electrical signal and power energy between stator and a rotor or vice versa. They are comprised of 3 or more graphite or metal contacts, mounted on the steel shaft .The contact brushes are all replaceable and are in graphite on Prisma and Navale series in copper on Scudo series.

� OPERATING TIME: The operating life of a slip ring depends on the rotation speed and the dynamic stability.

� CURRENT RATING: Capacity can be increasing by connecting in series or parallel two or more slip rings.

� BRUSHES IN GRAPHITE (Prisma and Navale line): They are mainly used on low-medium speed applications. They are most used when more circuits are required as they ensure a very good connection, as they are resistant to both low and high temperatures and aggressive environments with chemicals and/or humidity present.

� SPEED OPERATION: Max rotation speed 20 turns 1’.

Picture N° rings Code Dimensions “A”

3 30402091 180

4 30402092 195

5 30402093 210

6 30402094 225

7 30402095 240

8 30402096 255

9 30402097 270

10 30402098 285

11 30402099 300

12 30402100 315

13 30402101 330

14 30402102 345

15 30402103 360

Technical data

�Rated insulation voltage Ui 690V

�Rated operating voltage Ue 500Vac

�Rated operating current 20A Intermittent working 30A.

�IP51 close frame version withprotection rated IEC/EN60529

�Modularity:from 3 up to 15 80 mm Ø rings

�Copper brushes

�42 mm Ø shaft

�Pvc Ø147 mm housing and terminals cover

�Ambient temperature:+60°C/-30°C

Scudo / G75-G100

Warning horns page 43

Picture Line Supply Consumption Code

G75 Ø 75mm G75 24 AC 190 mA G75.24

G75 48 AC 80 mA G75.48

G75 110 AC 28 mA G75.110

G75 230 AC 20 mA G75.230

G75 24 DC 40 mA G75.24DC

G75 48 DC - G75.48DC

G100 Ø100mm G100 24 AC 415 mA G100.24

G100 48 AC 210 mA G100.48

G100 110 AC 90 mA G100.110

G100 230 AC 42 mA G100.230

available on request : Prisma line (open box), Navale line (aluminium housing) and spare parts (collectors, brushes etc etc..)

Box

G 75G100

1171000911710010

DimensionsTechnical data

�Continuos operation�Frequency: G75: 50 HzG100: 300÷350 Hz �Pressure (at 1 meter):G75: 88 dB (A) G100: 93.5 dB (A) �Wall mounted�Protection class IEC/EN 60529:G75: IP30 G100: IP65 double insulated�Terminal type:G75: 3 way terminal (2+T)G100: 2 way terminal

A B H

G75 Ø95.5 Ø76.5 56

G100 Ø120 Ø95.5 58

44

product description

Busbar system – trolley line TR60 and TR85 Giovenzana page 44 to 67

The “trolley system” series conductors rails are modern and safe system for energy and data transmission for various types of equipment such as: cranes - bridge cranes - conveyour belts - chain conveyors - etc...The “trolley system” complies with the relevant international standards ensuring operator safety, easy of installation and reliability.

Typical line schematic

ID Name Function

① Busbar PVC housing

② Trolley transmit the energy from the conductor to the load

③ Feed connect power supply to the conductors

④ Joint / Fixed point connect two busbars / create a fixed point

⑤ End Cap close and protect the busbar end

⑥ In-line feed avoid the voltage reduction

⑦ Hanger clamp connect the busbar to the brackets

⑧ Copper strip transmit the energy from the power supply to the trolley

Busbar line exampleand

module type

Straight : 3 or 4 meter module

90° curvestandard radius available orcustomized radius on request

Height drop available on request

EN

ER

GY

& D

ATA

tra

nsm

issio

n

�Worldwide installation: complies with the relevantinternational standards.� Safety: the conductors are protected and insulated bythe busbar.� Extra quality materials: self-extinguishing and high resistant strenght.� Easy & Fast installation: only a simple “click” (NO toolsrequired) is needed to mount almost all items.� Flexible: indoor or outdoor installation, all componentsare designed to tolerate different climate status.� Expansion possibilities: a lot of possibilities to expandor customize your line

Busbar systemEnergy and data transmission

versions

Exploded & sectionview

45

Exploded & sectionview

Yellow colour

CONTINUOUS CONDUCTORS: the conductors strip are pulled from a coil without jointsinto the already installed casing.

long life, minimal and constant voltage reduction! The absence of joints between the

conductors permits a long life brushes, plus minimal deposit and ohmmic resistance.

Versions

Blue colour

PRE-MOUNTED CONDUCTORS: the conductors are already inserted in the plastic casing.

very fast installation! Since the conductors are already inserted into the housing, it is only

necessary to joint each section of the busbar.


EN

ER

GY

& D

ATA

tra

nsm

issio

n

joint

withoutjoint

size

46

Size

� TR60 40 - 60 amp � TR85 40 – 70 – 100 – 140 - 200 amp

Conductor’s slot (max 5)

Gasket’s slot (option)

Power supply

Type ID

Phase R/L1

Phase S/L2

Phase T/L3

Neutral N

Ground PENote: PE conductor ID marked on busbar side

Scale 1:1 Scale 1:1

One way trolley insertion pin

56

85

60

402.7

4

17

11


EN

ER

GY

& D

ATA

tra

nsm

issio

n

Line constructionBusbar systemEnergy and data transmission

47

EN

ER

GY

& D

ATA

tra

nsm

issio

n

Line construction

To decide the size of trolleys is necessary to consider:� Maximum current in service� Devices (cage motors, slip rings motors, resistors, electronic starters)� Starting current of the devices� Maximum ambient temperature� The distance between device to the nearest power feed� Voltage and admissible voltage drop in continuous and in starting service� Type of current� Devices cycle operations (load factor)

Calculation of the voltage drop

Voltage drop should not exceed 5% of rated voltage in normal operating service

Three phase alternate current: Legenda:

∆u∆u%

ILtZU

======

voltage dropvoltage dropcurrent intensitylenght of sectionimpedencevoltage

[V][%][A][m][Ω/m][V]

Power feed: busbar track length

A proper disposal of power feed points minimize the voltage reduction.If “L” is the lenght of the line, “Lt” is the track maximum length to consider the voltage reduction.

ABCD

LtLtLtLt

====

LL/2L/6

L/10

with ending/starting power feedwith in-line power feedwith power feed at 1/6 from each endwith three power feed at L/2 and L/10 from each end

A B

C D

Line constructionBusbar systemEnergy and data transmission

48

EN

ER

GY

& D

ATA

tra

nsm

issio

n

Current in continuous service

Specify the number of the devices which work simultaneously to calculate the corresponding current:

In = I1 + I2 + I3 + ….

The current can be determined from the devices power [W] that for a three phase system is:

Legenda:

InPuȠU

cosϕ

=====

current consumptionpower devicesdevices performanceoperating voltagepower factor

[A][W]

[V]

In the absence of information on the operation of simultaneous devices, consider the following table:

Numbers of in-line lifting device

Lifting equipment in use

1st engine 2nd engine 3rd engine 4th engine

max power engine (○) decreasing power engine (○)

1 X X

2 X X X

3 X X X

4 X X X X

5 X X X X

No. 2 lifting equipmentoperating simultaneously

X X X X

(○) about Ƞ motors connected in parallel with rated current In’, consider In = Ƞ ● In’

Starting current

Calculate the numbers of the devices started simultaneously and the device already in service, then calculate the corresponding current. If the starting current is unknown, proceed with the following approximation:

for a single user

as a general rule, consider:K = 5 to 6 for cage motorsK = 2 for winding motorsK = 2 for inverters (frequency converters)

In the absence of information on the operation of simultaneous devices, consider the following table:

Numbers of in-line lifting device

Lifting equipment in use

1st engine 2nd engine 3rd engine 4th engine

Ia In Ia In Ia In Ia In

1 X X

2 X X X

3 X X

4 X X X

5 X X X X

No. 2 lifting equipmentoperating simultaneously

X X X X

Other items

Power feed from 40A to 140A TR8503A4 1

End cap from 40A to 200A TR8506A 1

Hanger clamp from 40A to 140A plastic material TR8502 (○) 17

Hanger clamp from 40A to 140A steel material TR8525 (○) 17

Joint from 40A to 200A plastic material

(the quantity of the joints is equal to the quantity of the

busbar +1)

TR8504 (○) 10

(○) add no. 2 hanger clamp for R.1200 to 1.800mm curve

add no. 3 hanger clamp for R.2.200mm curve

Curve

Curve R.2.200mm = L 3.455mm TR8529704D90 1

Curve R.1.200mm = L 1.885mm TR8529704A90 1

Total busbar lenght: ① + ② + ③ sector = 31m

Total busbar 4m module TR85704C 4

Total busbar 3m module TR85704C3 5

③ section 7,0m = 7.000mm

15.250-290 (end cap) = 14.960mm

No.3 busbar 4m = 12.000mm

No.1 busbar 4m = 4.000mm TR85704C 1

No.1 busbar 3m = 3.000mm TR85704C3 1

7.000mm – 7.000mm = 0

② section 8,750 = 8.750mm

No. 3 busbar 3m = 9.000m TR85704C3 3

9.000mm – 8.750mm = +250mm (excess)

TR85 BLUE line exampleBusbar systemEnergy and data transmission

49

EN

ER

GY

& D

ATA

tra

nsm

issio

n

① section 15,250m = 15.250mm

15.250-85 (power feed) = 15.165mm

No.3 busbar 4m = 12.000mm

No.3 busbar 4m = 12.000mm TR85704C 3

No.1 busbar 3m = 3.000mm TR85704C3 1

12.000mm+3.000mm = 15.000mm-15.165 = -165mm (lack)

TR85 Blue line (pre-mounted conductors) 70 A – 4 conductors, order example:

To define line overall length is necessary to consider the standard modular length of the busbar, except the curves.These can be obtained with the 3 or 4 meters module.The real length of the line will therefore be highter or lower than the theoretical length assumed or required.

Example of order and composition of a line according to the diagram:

Busbar systemEnergy and data transmission Code Map

50

ID Name Function Specifications 40 A 60 A 40 A 60 A

① Busbar PVC housing

3 meters module 4 conductors

-

TR60404C3 TR60604C3

3 meters module 5 conductors TR60405C3 TR60605C3

4 meters module 4 conductors

TR6000 (w/o conductors)

TR60404C TR60604C

4 meters module 5 conductors TR60405C TR60605C

Curved 90° (□)R.1.2 meters

4 conductorsTR60A90 TR60404A90 TR60604A90


4 conductorsTR60B90 TR60404B90 TR60604B90


4 conductorsTR60C90 TR60404C90 TR60604C90


4 conductorsTR60D90 TR60404D90 TR60604D90

② Trolleytransmit the energy from the

conductor to the load

4 conductors TR6004 (25 A)

5 conductors TR6005 (25 A)

③ Feedconnect power supply to the

conductors

4 conductors

TR6003

TR6003A4

5 conductors TR6003A5

④Joint / Fixed

pointconnect two busbars / create a

fixed point

Joint TR6001 (PA66)

Fixed point TR6014

⑤ End Cap close the busbar end TR6006 TR6006A

⑥ In-line feed avoid the voltage reduction

4 conductors

TR6008

TR6008A4

5 conductors TR6008A5

⑦ Hanger clampconnect the busbar to the

bracketsPA66 material

TR6002 (PA66) – TR6020 (steel)every 1.33 meter max

⑧ Copper striptransmit the energy from the

power supply to the trolleyCS40 CS60 -(copper strip already inserted)

- Support bracket support the line

Rail fixing

L 350mm TR8550

L 500mm TR8551

L700 mm TR8552

Wall fixing

L 350mm TR8555

L 500mm TR8556

- Towing armfixed to the mobile device

permits to tow the trolleysTR8510

-Towing arm

bracketpermits to the mobile device to

tow the trolleyTR6007

-Double trolley

supportconnects two trolley in parallel

to increase current ratingTR6013

- Gasket IP23 additional protection IP13>IP23 TR6012

-Copper strip

trolley insertionspecific tool to insert easily the

copper strip into the busbarTR6011 - (copper strip already inserted)

- De-coil unit unwind easily the copper rolls TR8513 - (copper strip already inserted)

- Inspection joint allow easy trolley’s replacement - -

- Section joint Isolate two side track -

- Brushes spare parts - - - -

TR60

YELLOW line BLUE line

EN

ER

GY

& D

ATA

tra

nsm

issio

n

Busbar systemEnergy and data transmission Code Map

51

70 A 100 A 140 A 40 A 70 A 100 A 140 A 200 A

- - - TR85404C3 TR85704C3 TR851004C3 TR851404C3 TR852004C3

- - - TR85405C3 TR85705C3 TR851005C3 TR851405C3 TR852005C3

TR85704 (*) TR851004 (*) TR851404 (*) TR85404C TR85704C TR851004C TR851404C TR852004C

TR85705 (*) TR851005 (*) TR851405 (*) TR85405C TR85705C TR851005C TR851405C TR852005C

TR8529A90 TR8529404A90 TR8529704A90 TR85291004A90 TR85291404A90 -

TR8529B90

(R. 1400mm)

TR8529404B90

(R. 1400mm)

TR8529704B90

(R. 1400mm)

TR85291004B90

(R. 1400mm)

TR85291404B90

(R. 1400mm)-

TR8529C90 TR8529404C90 TR8529704C90 TR85291004C90 TR85291404C90 -

TR8529D90 TR8529404D90 TR8529704D90 TR85291004D90 TR85291404D90 -

TR8511 (35 A) / TR8518 (70 A) / TR8532 (70A articulated used for line with curved busbar)

TR8512 (35 A) / TR8519 (70 A)

TR8503

TR8503A4 TR8533A4

TR8503A5 TR8533A5

TR8501 (PA66) / TR8524 (steel) TR8504

TR8527.1

TR8506 TR8506A

TR8547

TR8502 (PA66 not for 200 A) / TR8525 (steel)every 2meters max from 40 to 140 amp - every 1 meter max for 200 amp

(*) (*) (*)- (copper strip

already inserted)

- (copper strip

already inserted)

- (copper strip

already inserted)

- (copper strip

already inserted)

- (copper strip

already inserted)

TR8550

TR8551

TR8552

TR8555

TR8556

TR8510

TR6007

TR8523

TR8505

TR8514 - (copper strip already inserted)

TR8513 - (copper strip already inserted)

TR8528 -

TR8545 TR8545B

TR8517 (35 A) / TR8520 (70 A)

TR85

YELLOW line BLUE line

(*) copper rolls already included in the busbar code(□) on request available other curve radius

EN

ER

GY

& D

ATA

tra

nsm

issio

n

Busbar systemEnergy and data transmission TR60 series 40-60A

52

Blue linepre-mounted conductors

Yellow lineconductors to be pulled

min. qty

Name SpecificationsN°

conductors 40 A 60 A 40 A 60 A

Straightbusbar

� Self-extinguishing material� One-way trolley insertion pin.

←→L = length

Lmeters

34 TR60404C3 TR60604C3 -

3-4meters

5 TR60405C3 TR60605C3 -

44 TR60404C TR60604C

TR60005 TR60405C TR60605C

90°curvedbusbar

� Self-extinguishing material� One-way trolley insertion pin.

R = radius

Rmeters

1.2

4

TR60404A90 TR60604A90 TR60A90

11.5 TR60404B90 TR60604B90 TR60B90

1.8 TR60404C90 TR60604C90 TR60C90

2.2 TR60404D90 TR60604D90 TR60D90

Feed

�Fast assembly�M25 cable gland equipped

4 TR6003A4TR6003 1

5 TR6003A5

In-linefeed

�Fast assembly (+screw)�M25 cable gland equipped

4 TR6008A4TR6008 1

5 TR6008A5

End cap �Self tapping screw fix

4TR6006A TR6006 1

5

Copperstrip

-

-CS40

40 A /10mm²CS60

60 A /15mm² (○)

Note (○) “copper strip quantity”: will be supplied the total meters according busbar quantity

Click!

Click!

� TR60 40 amp60 amp

Code table list page 1/2

Dimensions see pag 58

EN

ER

GY

& D

ATA

tra

nsm

issio

n

Busbar systemEnergy and data transmission TR60 series 40-60A

53



min. qty

Name Picture Specifications note 40 A 60 A 40 A 60 A

Trolley25 A

� 25A load current�Self-extinguishing mat.�Fully insulated�Metal graphite brushes�One-way insertion pin�Easy cable wiring

4 conductors TR6004 1

5conductors

TR6005 1

Doubletrolley

support

�Connects two trolleys in parallel to increasecurrent rating

TR6013 1

Hangerclamp

�Fast connection�Every 1.33 meters MAX

PA66material

TR6002 1

Steelmaterial TR6020 1

Joint

�Fast assembly

TR6001 1

Fixedpoint

�Fast assembly

TR6014 1

Towingarm

Fixed to the mobile device permits to tow the trolley�Galvanizedsteel material

TR8510 1

Towingarm

bracket

Fixed to the trolley permits to the mobile device to tow the trolley�Painted blacksteel material

TR6007 1

GasketIP23

Additional prot. IP13>IP23�PVC material�Resistance to cold -30°�Stretching 340%�Hardness shore A 81

TR6012 (●)

Strip insertion

trolley

Specific tool to easily insert the copper strip into the busbar

- TR6011 1

De-coilunit

Specific tool to easily unwind the copper rolls - TR8513 1


Click!

Click!

Note (●) “gasket IP23 quantity”: (for order please consider twice the length of the line)

Click!

� TR60 40 amp60 amp

Code table list page 2/2

EN

ER

GY

& D

ATA

tra

nsm

issio

n

Busbar systemEnergy and data transmission TR85 series 40-70-100-140-200A

54



min. qty

Nam

e

Specifications N°

cond

ucto

rs40 A 70 A 100 A 140 A 200 A 70 A 100 A 140 A

Stra

ight

busb

ar

� Self-extinguishingmaterial� One-way trolley insertion pin.

←→L = lenght

Lmeters

copper strip rolls already incleded in busbar code

34 TR85404C3 TR85704C3 TR851004C3 TR851404C3 TR852004C3 -

3-4meters

5 TR85405C3 TR85705C3 TR851005C3 TR851405C3 TR852005C3 -

44 TR85404C TR85704C TR851004C TR851404C TR852004C TR85704 TR851004 TR851404

5 TR85405C TR85705C TR851005C TR851405C TR852005C TR85705 TR851005 TR851405

90°c

urve

dbu

sbar

�Self-extinguishing material� One-way trolley insertion pin.

R = radius

Rmeters

1.2

4

TR8529404A90 TR8529704A90 TR85291004A90 TR85291404A90 - TR8529A90

11.4 TR8529404B90 TR8529704B90 TR85291004B90 TR85291404B90 - TR8529B90

1.8 TR8529404C90 TR8529704C90 TR85291004C90 TR85291404C90 - TR8529C90

2.2 TR8529404D90 TR8529704D90 TR85291004D90 TR85291404D90 - TR8529D90

Feed

�M40 cable gland equipped

4 TR8503A4 TR8533A4TR8503 1

5 TR8503A5 TR8533A5

In-li

nefe

ed

�Pg29 cable gland equipped (not mounted)

TR8547 1

End

cap

�Self-tapping screw fixing

TR8506A TR8506 1

Join

t

TR8504 (PA66) TR8501 (PA66) – TR8524 (steel)

Sect

ion

join

t �N°2 Pg29 cable gland equipped�Insulating strip bars

TR8545B TR8545

� TR85 40-70-100-140-200 amp Dimensions see pag 62

Code table listpage 1/2

200amp

70..140 amp

EN

ER

GY

& D

ATA

tra

nsm

issio

n



min. qty

Nam

e

Picture Specifications Note 40 A 70 A 100 A 140 A 200 A 70 A 100 A 140A

35A

trol

ley � 35 or 70 A load

current�Self-extinguishing material�Fully insulated�Metal graphite brushes�One-way insertion pin�Complete of 1.5m cable CEI 20-22 NPI

4conductors

TR8511

15

conductorsTR8512

70 A

trol

ley 4

conductorsTR8518 – TR8532 (articulated used for line with curved busbar)

15

conductorsTR8519

Dou

ble

trol

ley

supp

ort

�Connects two trolleysin parallel to increasecurrent rating

TR8523 1

Han

ger

calm

p

�Fast connection�Every 2 meters MAXfrom 40 to 140 amp�Every 1 meter MAXfor 200A

Pa66material

TR8502 (not for 200 A)

1Steel

materialTR8525

Fixe

dpo

int

TR8527.1 1

Gas

ketI

P23

Additional prot.IP13>IP23�PVC material�Resistance to cold:

-30°�Stretching 340%�Hardness shore A 81

TR8505 (●)

Tow

ing

arm

Fixed to the mobile device permits to tow the trolley�Galvanizedsteel material

TR8510 1

Tow

ing

arm

brac

ket

Fixed to the trolley permits to the mobile device to tow the trolley�Painted blacksteel material

TR6007 1

Insp

ecti

onjo

int

With multiple trolleysallows easy maintenance or replacement of trolleys

- TR8528 1

Stri

p in

sert

ion

trol

ley Specific tool to insert

easily the copper into the busbar

- TR8514 1

De-

coil

unit Specific tool to easily

unwind the copper rolls- TR8513 1

Brus

hes

Spare parts

35 A TR8517

1

70 A TR8520

Busbar systemEnergy and data transmission TR85 series 40-70-100-140-200A

55


Note (●) “gasket IP23 quantity”: (for order please considertwice the length of the line)

� TR85 40-70-100-140-200 amp

Code table listpage 2/2

EN

ER

GY

& D

ATA

tra

nsm

issio

n

Click!

3 Fix the busbar


56

Mounting instructions

1 Fix the support bars

�TR60 max 1.33 meters �TR85 from 40 A to 140 A max 2 meters �TR85 200 A max 1 meters

Yellow line(conductors to be pulled)

2 Fix the hanger clamp

�set vertical positions moving up and down the bolt and tighten well

�NO tools required

6 Pull the conductors4 Apply all the joints

�TR60 no tools required�TR85 fixed by screws

5 Fix the copper strip to the insertiontrolley

�Drill the copper strip if not already provided with holes and fix it to the insertion trolley

�Drag the trolley using a rope�Repeat the operation for all the coductors�Drag one conductor one by one

9 Insert the trolley7 Cut the copper strip

�Cut the copper strip 50mm out from the busbar(line feed side)�Cut the copper strip flush with the busbar(end cap side)

8 Prepare the trolleys

�TR60: to be cabled: wire the trolley respecting the connections shown�TR85 Trolleys are already supplied with the wire

�One way insertion pin / press in the brushes�PE brush corresponding to the continuous black line on the busbar side

10 Mount the feed

�Fix the case to the busbar�Bend and drill (if not already drilled) the strips�Cable the strips as shown/tight the cable gland

11 Mount the end cap

�Fix the end capwww.youtube.com/user/GiovenzanaInt

4c Close & fix the cover4a If needed mount the in-line feed

�Put both sides on the busbar�Pull & bend the copper conductors�Operation recommended to do before point 5

4b Cable the line

�Cable the strips as shown �Close and fix both cover�Tighten the cable gland

L 1

L 2NL 3

P E

E n d c a p s i d eF e e d s i d e

NL 2 L 3

L 1 P E

NEED HELP?Ask to our technical service

EN

ER

GY

& D

ATA

tra

nsm

issio

n

3 Fix the busbar

Busbar systemEnergy and data transmission Mounting instructions

1 Fix the support bars

�TR60 max 1.33 meters �TR85 from 40 A to 140 A max 2 meters �TR85 200 A max 1 meters

Blue line(pre-mounted conductors)

2 Fix the hanger clamp

�set vertical positions moving up and down the bolt and tighten well

�NO tools required

4 Fix each conductors strip

�Fast connection using dedicated clamps

7 Insert the trolley

6 Prepare the trolleys

�TR60: to be cabled: wire the trolley respecting the connections shown�TR85 Trolleys are already supplied with the wire

8 Mount the feed

�Fix the conductors of each legs�Apply joint / cable the strips as shown�tight the cable gland and close with the cover

9 Mount the end cap

�Fix the end cap / apply joint

3c Close & fix the conver3a If needed mount the in-line feed 3b Cable the line

L 1

L 2NL 3

P E

NEED HELP?Ask to our technical service

57

5 Apply all the joints

�TR60 no tools required�TR85 fixed by screws

�One way insertion pin / press in the brushes�PE brush corresponding to the continuous black line on the busbar side

�Fix the conductors of each side�Apply joint

�Cable the strips as shown �Close and fix both cover�Tight the cable gland

NL 2 L 3

L 1 P E

EN

ER

GY

& D

ATA

tra

nsm

issio

nwww.youtube.com/user/GiovenzanaInt

compatible with yellow line(conductors to be pulled)


58

TR60 Drawings & Dimensions

� TR6000 TR60 line busbar

compatible with blue line(pre-mountedconductors)

� TR60404C3-TR60405C3-TR60404C-TR60405C� TR60604C3-TR60605C3-TR60604C-TR60605C

TR60 line pre-mounted busbar

Line Amp N° conductors Bar length “L”

TR60 40= 40 amp60= 60 amp

4C = four5C= five

No extension = 4meters3= three meters complete of terminal clamp for each conductors

Radius[meters] 40 amp 60 amp

1.2 � TR60404A90 � TR60604A90

1.5 �TR60404B90 �TR60604B90

1.8 � TR60404C90 � TR60604C90

2.2 �TR60404D90 �TR60604D90

4 conductors only 90°

90°

Radius[meters] 40 amp

1.2 � TR60A90

1.5 �TR60B90

1.8 � TR60C90

2.2 �TR60D90

4 conductors only can be pulled

EN

ER

GY

& D

ATA

tra

nsm

issio

n



59


� TR6001 TR60 line joint � TR6002 TR60 line hanger clamp

� TR6003 TR60 line feed

5x M5x8

2x 3.5x9.5 self tapping

M25


� TR6003A4-TR6003A5 TR60 line pre-mounted feed

� TR6003A5 5 polesL1-L2-L3-N-PE� TR6003A4 4 poles

L1-L2-L3-PE

� TR6004 - TR6005 TR60 line trolley

�

TR6004

4 polesL1-L2-L3-PE

�

TR6005

5 polesL1-L2-L3-N-PE

connection rif. markings

EN

ER

GY

& D

ATA

tra

nsm

issio

n


60


complete of:• M25 cable gland• 5x terminal clamp

� TR6008 TR60 line in-line feed

2xM8x25

� TR6006 TR60 line end cap

� TR6007 TR60-85 line towing arm bracket



� TR6006A TR60 line pre-mounted end cap

� TR6008A4-TR6008A5 TR60 line pre-mounted in-line feed

�

TR6008A4

4 polesL1-L2-L3-PE

�

TR6008A5


complete of terminal clamp for each conductors

6x M25 closed spot

6x M25 closed spot

EN

ER

GY

& D

ATA

tra

nsm

issio

n



61

for order please consider twice the length of the line



� TR6012 TR60 line gasket IP23

� TR6013 TR60 line double trolley support

� TR6014 TR60 line fixed point

M8x50

� TR6011 TR60 line strip insertion trollety

� CS40

40 amp10 mm²

1 x 10 mm²

� CS60

60 amp15mm²

1.5 x 10 mm²

copper conductors

screw fix

� CS40-CS60 TR60 line copper strip

� TR6020 TR60 line hanger clamp (steel)

EN

ER

GY

& D

ATA

tra

nsm

issio

n

Busbar systemEnergy and data trasmission

62




Radius[meters] 40 amp 70 amp 100 amp 140amp

1.2 � TR8529404A90 � TR8529704A90 � TR85291004A90 � TR85291404A90

1.4 � TR8529404B90 � TR8529704B90 � TR85291004B90 � TR85291404B90

1.8 � TR8529404C90 � TR8529704C90 � TR85291004C90 � TR85291404C90

2.2 � TR8529404D90 � TR8529704D90 � TR85291004D90 � TR85291404D90

4 conductors only 90°

90°

Radius[meters] 40 amp

1.2 � TR8529A90

1.4 �TR8529B90

1.8 �TR8529C90

2.2 �TR8529D90

4 conductors only can be pulled

� TR85404C3-TR85405C3-TR85404C-TR85405C� TR85704C3-TR85705C3-TR85704C-TR85705C� TR851004C3-TR851005C3-TR851004C-TR851005C� TR851404C3-TR851405C3-TR851404C-TR851405C� TR852004C3-TR852005C3-TR852004C-TR852005C

TR85 line pre-mounted busbar

Line AmpN°

conductorsLength bar

“L”

TR85

40= 40 amp70= 70 amp100= 100 amp140= 140 amp200= 200 amp

4C = four5C= five

No extension = 4meters3= three meters

Line AmpN°

conductorsBar lenght

“L”

TR8570= 70 amp100= 100 amp140= 140 amp

4C = four5C= five

4meters

� TR85704-TR85705� TR851004-TR851005� TR851404-TR851405

TR85 line busbar

EN

ER

GY

& D

ATA

tra

nsm

issio

n



63



� TR8501 TR85 line joint � TR8502 TR85 line hanger clamp

� TR8503 TR85 line feed � TR8503A4-TR6003A5� TR8533A4-TR8533A5

TR85 line pre-mounted feed

� TR8503A5(40…140amp)�TR8533A5

(200amp)


� TR8503A4(40…140amp)�TR8533A4

(200amp)

4 polesL1-L2-L3-PE

� TR8504 TR85 line joint

� TR8505 TR85 line gasket IP23

� TR8506A TR85 line pre-mounted end cap

� TR8506 TR85 line end cap

� TR85010 TR60-85 line towing arm

for order please consider twice the length of the line

EN

ER

GY

& D

ATA

tra

nsm

issio

n



64



� TR8511-TR8512 TR85 line 35 amp trolley

� TR8513 TR60-85 line de-coil unit

� TR8517-TR8520 TR85 line brush

� TR8505 TR85 line 70 amp trolley

� TR8523 TR85 line double trolley support

�

TR8511

4 polesL1-L2-L3-PE

�

TR8512


Ø800

58

38

330

� TR8514 TR85 line strip insertion trolley

�

TR8517

for 35 amptrolley

�

TR8520

for 70 amptrolley

�

TR8518

4 polesL1-L2-L3-PE

�

TR8519


�Ball bearing wheels�Complete of L 1500mm CEI 20-22 NPI cable

�Ball bearing wheels�Complete of L 1500mm CEI 20-22 NPI cable

EN

ER

GY

& D

ATA

tra

nsm

issio

n

�

TR8532

4 polesL1-L2-L3-PEarticulatedfor curves

TR6007



65



� TR8524 TR85 line joint (steel)

� TR8527.1 TR85 line fixed point � TR8528 TR85 line inspection joint

� TR8525 TR85 line hanger clamp (steel)

screw 8x70

� Used for maintenance operation, it allows easy removal of the trolley:1) disconnect the trolley to be removed2) place the trolley in the inspection joint3) remove the half joints and half busbar (side “A” without ribs)4) replace the trolley5) close the busbar and joints6) place the adhesive rubber gasket

side “A” without ribs

side “B”with ribs

EN

ER

GY

& D

ATA

tra

nsm

issio

n

adhesive rubber gasket



66



two arm clip kit included

�

TR8550

L= 350mm

�

TR8551

L= 500mm

�

TR8552

L= 700mm

� TR8555-TR8556 TR60-85 line support bracket (wall fixing)

�

TR8555

L= 350mm

�

TR8556

L= 500mm

� TR8550-TR8551-TR8552 TR60-85 line support bracket (rail fixing)

� TR8547 TR85 line in-line feed

Pg29 cable gland included(not mounted)

� TR8545-TR8545B TR85 line section joint

Insulating strip bars

�

TR8545

yellow

�

TR8545B

blue

EN

ER

GY

& D

ATA

tra

nsm

issio

n

M o u n t i n g

e x a m p l e


67

Technical data

General characteristics

Line / SizeTR60 TR85

40 60 40 70 100 140 200

Operating current 23°C 40A 60A 40A 70A 100A 140A 200A

Comply with standards CEI EN 60439-1, CEI EN 60439-2, CEI EN 60695-2-1, CEI EN 60570

Markings

Rated operating voltage [Ue] 600 Vac

Frequency 50 Hz

Conditional rated short circuit withstand current 10 kA

Fuse rating gG 40A 60A 40A 70A 100A 160A 200A

Protection class CEI EN 60529 IP13 (IP23 with gasket accessories)

Flammability resistance

UL94 V0

Cei EN 60695-2-1 [°C] 960

Ambienttemperature

operating -30 °C + 55 °C

storage -30 °C + 70 °C

Admissible trolley speed 200 m/min1

Copper strip section [mm²] 10 15 9.3 15.5 21.7 31 46.5

Resistance [Ω/m 10-4] 17 11.33 18.27 10.96 7.83 5.48 3.65

Impedence [Ω/m 10-4] 17.09 11.38 18.36 11.01 7.87 5.55 3.67

PVC busbar characteristics

Material rigid PVC

Self-extinguish

UL 94 V0

DIN 4102 B2

D.M.6/7/83 CI

Ultimate tensile strenght ISO R527 23 °C 430 kg/cm3

Yield point ISO R527 23 °C 460 kg/cm2

Modulus of elasticity ISO R178 23 °C 30000 kg/cm2

Impact resistance DIN 53453 unbroken

Dielectric strenght ASTM 149 25 kV/mm

Softening temparature – Vicat ISO R306 49N 82 °C

Conductors bars weight table (complete of conductors)

Line / SizeTR60 TR85

40 60 40 70 100 140 200

N° of conductors

4 1.035 kg/m 1.219 kg/m1.680 kg/m

1.902 kg/m

2.122 kg/m

2.454 kg/m

3.010 kg/m

5 1.127 kg/m 1.357 kg/m1.764 kg/m

2.050 kg/m

2.305 kg/m

2.730 kg/m

3.423 kg/m

EN

ER

GY

& D

ATA

tra

nsm

issio

n

68

Festoon system – line 30 – 41 and 41 inox Giovenzana page 68 to 79

The festoon system is the traditional system for energy transmission for various type of handling equipment. One of the most popular is the overhead crane where the festoon lines transmit the signals to control the movement of the crane.Line 30 and 41 Giovenzana are made of a “C”- rail bar fixed along the crane’s movement line. The signal cable is supported by the trolley that slides inside the “C”-rail bar.Both lines 30 and 41 offer a complete selection of items and accessories to customize them according Customer needs.

Typical line schematic:

ID Picture Name

① C-rail bar

②Support arm and support bracket

③ Towing trolley

④ Trolley

⑤ Joint

Festoon line module type

Straight:4 meters module

(3 meters for stainless steel)

Curve: 90° curve radius 1.5 m(only line 41)

Festoon systemEnergy and data transmission

C- rail bar system

Line Characteristic Markings

30 � Bar height: 30 mm � Load capacity: 100 kg/m

41 � Bar height: 41 mm � Load capacity :140 kg/m

41 stainless steel � Bar height: 41 mm � Load capacity :140 kg/m � Stainless steel material

⑥ Head clamp

⑦ End Cap

⑧ Cable

⑨ End stop

①

③

④

②

⑤

⑥

⑦⑨

⑧

⑦⑨

product descriptionLine 30 – 41 – 41 stainless steel

EN

ER

GY

& D

ATA

tra

nsm

issio

n

69

Line 30-41Code table listFestoon system

Energy and data transmission

Description note

Line 30 (load capacity 100 kg/m Line 41 (load capacity 140 kg/m)Min. qtyCode Picture

Codestandard

Codestainless steel

Picture

C-Rail bar

straight 4m 30607001 30602001/4 30602061 (3m)3-4

meters90° curved radius 1.5 m - 30602054 (○) -

Track support bracket 30607017 30602004 - 1

Track support bracket 30607003 30602003 30602063 1

Joint

standard 30607002 30602002 30602065

130602034 30602062double for

track >50m -

End stop 30607005 30602038 30602068 1

Towing trolley

single execution 30607007 30602091 30602067

1double

execution - 30602020 -

Trolley with safety plug and socket connection

16 poles 30607008 30602036 -1

24 poles 30607019 30602040 -

Trolley (steel)

ball bearing wheels 30607010 30602086 -

10PA

wheels 30607009 - -

Trolley (PA)

55 mm saddle 30607011 30602069 30602064

1076 mm saddle - 30602070 -

Round cable trolley PA/steel 30607021 - - - 10

Head clamp

55mm saddle 30607020 30602071 30602066

176mm saddle 30607006 30602072 -

Bracket

500 mm 30607001/05 - -- 1

800 mm 30607001/08 - -

Support arm bracket (hanger) 30607004 - - - 1

Support arm clip (claw) 30607012 - - - 1

End cap 30607015 - - - 1

Cable clip 30607016 - - - 10

(○) may requiremechanical adjustment during line assembly

EN

ER

GY

& D

ATA

tra

nsm

issio

n

Picture Description Code Dimensions

C-Rail bar�Material: galvanized steel�Length: 4 m�Weight: 5 kg

30607001

Bracket�Material:

galvanized steel

30607001/05(length 0.5 m)30607001/08(length 0.8 m)

Jointto connect a C-rail and suitable for supporting the track�Material: galvanized steelScrews M5x10 included

30607002

Track support bracket2 pcs�Material: galvanized steel�Max support spacing: 1 mscrews not included

30607003

Support arm bracket (hanger)�Material:

galvanized steel

30607004

End stop�Material: PA6

30607005

Line 30Load capacity: 100 kg/m - drawings & dimensionsFestoon system


EN

ER

GY

& D

ATA

tra

nsm

issio

n

70




Head clamp�Material: PA

30607020(55 mm saddle)

30607006(76 mm saddle)

Towing trolley�Material: galvanized steel�Steel rollers with ball-bearing�68 mm steel saddle

30607007

Trolley with safety plug and socket connectionTo connect the festoon system to the pendant station�68 mm saddle

30607008(16 poles)

30607019(24 poles)

Trolley (steel)�Material: galvanized steel�68 mm steel saddle

30607009(PA wheels)30607010

(ball-bearing wheels)

Trolley (PA)�Material: PA�PA rollers�55 mm PA material saddle

30607011

Support arm clip (claw)�Material: galvanized steel(need n° 2 for every bracket)

30607012

71

EN

ER

GY

& D

ATA

tra

nsm

issio

n

X:93 for 16poles

120 for 24poles

72




End cap 30607015

Cable clip 30607016

Track support bracketCeiling fixing 2 pcs�Material: galvanized steel�Max support spacing: 1 mscrews not included

30607017

Round cable trolley�Galvanized steel trolley upper body with PA saddle�Steel rollers with ball-bearing�Swinging & rotating saddle�Cable diameter:

min 10 – MAX 40 mm

30607021

EN

ER

GY

& D

ATA

tra

nsm

issio

n


C-Rail bar�Material: galvanized steel�Length: 4 m�Weight: 8 kg

30602001/4

90° curved bar�1.5 meters radiusmay require mechanical adjustmentduring line assembly

30602054

Jointto connect a C-rail and suitable for supporting the track�Material: galvanized steelScrews M5x10 included:No. 4 for singleNo. 8 for doubleUse double for track >50meters

30602002(standard)30602034(double)

Track support bracket2 pcs�Material: galvanized steel�Max support spacing: 1 mscrews not included

30602003

Track support bracketCeiling fixing 2 pcs�Material: galvanized steel�Max support spacing: 1 mscrews not included

30602004

Towing trolley�Material: galvanized steel�steel rollers with ball-bearing�68 mm steel saddle

30602091(single)

30602020(double)



EN

ER

GY

& D

ATA

tra

nsm

issio

n

double

standard

double

Top view

single

single

double

73doublesingle



Trolley with safety plug and socket connectionTo connect the festoon system to the pendant station�68 mm steel saddle

30602036(16poles)

30602040(24poles)

End stop�Material: PA6

30602038

STAINLESS STEEL

C-Rail bar�Material: stainles steel�Length: 3 m�Weight: 8 kg

30602061

STAINLESS STEEL

Jointto connect a C-rail and suitable for supporting the track�Material: stainless steelstainless screws M5x10 includedNo. 4 for singleNo. 8 for doubleUse double for track >50meters

30602065(standard)30602062(double)

STAINLESS STEEL

Track support bracket2 pcs�Material: stainless steel�Max support spacing: 1 mscrews not included

30602063

STAINLESS STEEL

Trolley (PA)�Material: PA�PA rollers�55 mm PA material saddle

30602064

Line 41Load capacity: 140 kg/m - drawings & dimensions

74

EN

ER

GY

& D

ATA

tra

nsm

issio

n

double

single

single

double

X:93 for 16poles

120 for 24poles



STAINLESS STEEL

Head clamp�Material:

PA – stainless steel�55 mm PA material saddle

30602066

STAINLESS STEEL

Towing trolley�Material: stainless steel�steel rollers with ball-bearing�68 mm steel saddle

30602067

STAINLESS STEEL

End stop�Material:PA6 – stainless steel screw

30602068

Trolley (PA)�Material: PA�PA rollers�55 or 76 mm PA saddle

30602069(55 mm saddle)

30602070(76 mm saddle)

Head clamp�Material: PA�55 or 76 mm PA saddle

30602071(55 mm saddle)

30602072(76 mm saddle)

Trolley (steel)�Material: galvanized steel�68 mm steel saddle

30602086

Line 41Load capacity: 140 kg/m - drawings & dimensions

75

EN

ER

GY

& D

ATA

tra

nsm

issio

n

76

Festoon system – line wire-rope Giovenzana page 76

The festoon system is the traditional system for energy transmission for various type of handling equipment.Line wire-rope Giovenzana uses a rope to support the trolleys carrying the cable that supplies energy to the mobile device.


Wire -rope system


Wire-rope Rope diameter:8 mm

Travel speed:40 m/min.

Trolley type:for flat or round cable

Trolley loadcapacity: 8 kg

Picture Description CodeMin. qty

Dimensions

FLAT CABLE

Twin roller trolley�Material:

PA6- galvanized steel�Type of roller: PA�Rotating 55 mm

plastic saddle�Range 30 mm�Speed 40 m/min.

30604003 10

FLAT CABLE

One roller trolley�Material:

PA6- galvanized steel�Type of roller: PA�Rotating 55 mm

plastic saddle�Range 30 mm�Speed 40 m/min.

30604005 10

ROUND CABLE

One roller trolley+ metal cable clip�Material:

PA6- galvanized steel�Type of roller: PA�Cable Ø max: 18 mm�Speed 40 m/min.

30604007 10

product description - contenentsLine wire-rope

EN

ER

GY

& D

ATA

tra

nsm

issio

n

Festoon system – line I-beam Giovenzana page 77 - 78

The festoon system is the traditional system for energy transmission for various types of handling equipments.Line I-beam Giovenzana uses the beams of the mobile device to support the trolleys carrying the cable that supplies energy to the mobile device.Line I-beam Giovenzana is suitable for installation in industries where heavy duty capabilities are required.For example it is used in:powering mobile equipment in steel mills, cranes, rolling mills, foundries, storage containers, etc… .

77


I-beam system


Light series Beam type:IPE-IPN 80÷100


Trolley load capacity:50 kg

Max cable capacity:70 mm

Heavy series Beam type:IPE-IPN 80÷120


Trolley load capacity:200 kg

Max cable capacity:50 mm

product description - contenentsLine I-beam

IPN

IPE

Light series

I-beamtype

I-beamsize

Seddle[mm]

Rollers TrolleyTowingtrolley

Headclamp

IPE

80

55PA 30606003 30606033

30606062steel 30606103 30606133

85PA 30606005 30606035

30606063steel 30606105 30606135

100

55PA 30606011 30606041

30606066steel 30606111 30606141

85PA 30606013 30606043

30606067steel 30606113 30606143

IPN

80

55PA 30606004 30606034

30606062steel 30606104 30606134

85PA 30606006 30606036

30606063steel 30606106 30606136

100

55PA 30606012 30606042

30606066steel 30606112 30606142

85PA 30606014 30606044

30606067steel 30606114 30606144

I-beamtype

I-beamsize

Seddle[mm]

Rollers TrolleyTowingtrolley

Headclamp

IPE

80

100 steel 30605001 30605013 30605025

160 steel 30605002 30605014 30605026

100

160 steel 30605005 30605017 30605027

180 steel 30605006 30605018 30605028

120

160 steel 30605009 30605021 30605029

180 steel 30605010 30605022 30605030

IPN

80

100 steel 30605003 30605015 30605025

160 steel 30605004 30605016 30605026

100

160 steel 30605007 30605019 30605027

180 steel 30605008 30605020 30605028

120

160 steel 30605011 30605023 30605029

180 steel 30605012 30605024 30605030

Heavy series

EN

ER

GY

& D

ATA

tra

nsm

issio

n

78

Festoon systemEnergy and data transmission dimensions

Line I-beam

Light series

Trolley

Towing trolley

Head clamp

Heavy series

Trolley

Towing trolley

Head clamp

EN

ER

GY

& D

ATA

tra

nsm

issio

n

79

Festoon systemEnergy and data transmission Line diagram

Line calculating schematic

Example “1" (blue colour) Total line length "LT" = 40 metersHeight "H" = 2 meters

Number of trolley/trucks = 12 pcs

Parking zone length "LP" = 1,2 metersRace length "LC=LT-LP" = 38,8 meters

Example “2" (red colour) Total line length "LT" = 40 metersHeight "H" = 1 meters

Number of trolley/trucks = 21 pcs

Parking zone length "LP" = 2,2 metersRace length "LC=LT-LP" = 37,8 meters

Line diagram

The diagram is used to determine the number of trolley necessary for the formation of the line, depending on its lenght.The height of the loop determines how many trolley are needed and thus their parking area. Where the parking area is toolong at the expense of running real user, it must increase the height of the loops, thus decreasing the number of trolleysrequired and therefore the parking area. To determine the cable lenght of a garland to increase by 10% the total lenght ofthe line and add enought to connect the two ends of the fixed and mobile users.

EN

ER

GY

& D

ATA

tra

nsm

issio

n

PVC flat cable anti-aging H07VVH6-F page 80

Particulary suitable for supply and control circuits, lifting and handling equipment.

80

Festoon systemEnergy and data transmission Conductors

Flat cable

GLI ULTIMI

QUATRO TRE

MISURE???

Characteristics

�Comply with: CEI 20-22 II (flame resistant) �Insulation class: 2/3

�Rated operating voltage: 400V �Rated insulation voltage: Uo/U 450/750V

�Max short circuit temparature: 160 °C �Operating temperature: -5 °C +70 °C

�Internal conductors with flexible PVC sheath progressively numbered, plus earth conductor(yellow/green)

�On request the cables can be supplied with a tinned red copper shield heat resistant up to 105 ° C (minimum requirement is 2000 m)

�Blue colour sheath�Finish the order code with “N” forthe black sheath

Flatcablegland

Standard 12903010

Ø 28.5 out 12903011

(○) Minimum supply 500m.

Code(final “N” forblack sheath)

N° conductorsX

cross section

Outer dimension[mm]

approx

Strand[N°/mm]

Weight[gr/m]approx

Total cross section[mm²)

Electricalresistance 20°C

[ohm/km]

Max current ambienttemperature 30°C [A]

Fixed place Moving place

CP0415AF 4X1.5 15X5.2

30X0.25

150 6

13.30

19.5 17

CP0815AF 8X1.5 29X5.5 300 12 12 10

CP1215AF 12X1.5 41X5 420 18 11 9.5

CP1615AF 16X1.5 54X8 510 24 10 8.5

CP1815AF 18X1.5 43X11 700 27 9.5 8

CP2415AF 24X1.5 51X13 1000 36 9 7.5

CP0425AF 4X2.5 21X5.7

50X0.25

240 10

7.98

26 22.5

CP0825AF 8X2.5 33X6 420 20 18 13

CP1225AF 12X2.5 50X7 640 30 17 12

CP1625AF 16X2.5 66X7 1000 40 16 11

CP1825AF (○) 18X2.5 50X13 1050 45 15 10

CP2425AF (○) 24X2.5 54X13 1100 60 14 9

CP0404AF 4X4 21X7.556X0.30

330 16 4.95 35 30

CP0804AF 8X4 38X5 550 32 4.95 24 19

CP0406AF 4X6 24X884X0.30

440 24 3.30 46 40

CP0806AF 8X6 38.5X8 742 48 3.30 32 25

CP0410AF 4X10 35X11 7X12X0.40 800 40 1.91 57 46

CP0416AF 4X16 36.5X12 7X18X0.40 1200 64 1.21 76 62

CP0425AF 4X25 43X13 7X28X0.40 1700 100 0.78 96 80

CP0435AF 4X35 54X14 7X39X0.40 2050 140 0.55 119 99

EN

ER

GY

& D

ATA

tra

nsm

issio

n

Round cable with dual strain relief steel ropes S05VVD7-F page 81

Made for heavy duty applications, in particular for pendant push button stations and moving electromechanical components.The two strain relief ropes avoid any stress on the cable; they are embedded, diametrically opposed to PVC sheath.

81

Festoon systemEnergy and data transmission Conductors

Round cable with dual strain relief cords

Characteristic

�Comply with: CEI 20-22 II (flame resistant) �Insulation class: 2/3

�Rated operating voltage: 230V �Rated insulation voltage: Uo/U 300/500V

�Max short circuit temparature: 160 °C �Operating temperature: -5°C +70°C

�Ø2mm steel strain relief ropes �Breaking point: 60kg/mm²

�Internal conductors with flexible PVC scheath progressively numbered, plus earth conductor(yellow/green)

Code(final “N” forblack sheath)

N°conductors

Xcross section

Outer cable ᴓ[mm]

approx

Strain reliefrope

dimension

Strand[N°/mm]

Weight[gr/m]approx

Total cross section[mm²)

Electricalresistance 20°C

[ohm/km]

Max current ambienttemperature 30°C [A]

Fixed placeMoving

place

CT0815AUAF 8X1.5 11.6 23.6

30X0.25

225 12

13.30

12 10

CT1215AUAF 12X1.5 14.4 26.4 315 18 11 9.5

CT1615AUAF 16X1.5 16 28 415 24 10 8.5

CT1815AUAF 18X1.5 17 29 470 27 9.5 8

CT2015AUAF 20X1.5 18 30 525 30 9 7.5

CT2415AUAF 24X1.5 21 33 620 36 8.5 7

strain relief steel ropes

�Blue colour sheath�Finalize the code with “N” for the black colour

EN

ER

GY

& D

ATA

tra

nsm

issio

n

Body disconnector switch base fixing page 82

Used to disconnect the power supply for maintenance operations. The door-interlock actuator comes with a locking knob, which can work with 3 locks (max) in complete safety. It is available in different size according to line range.

82

Festoon & Busbar systemEnergy and data transmission Complementary products

Disconnector switch

Characteristic

Code SQ032003B SQ063003B SQ125003B

Product ID SQ32 – Giovenzana Line SQ63 – Giovenzana Line SQ125 – Giovenzana Line

Picture

Functiondoor interlock - 3 poles on-off – 90° switching angle

(aux contact : neutral, protective earth “PE”, NC or NO available on request)

Comply with standards IEC 947-3, EN60947-3, UL508

Rated insulation voltage [Ui] 690V

Rated impulse withstand voltage [Uimp] 8kV

Rated thermal current [Ith] / in enclosed [Ithe] 40A 80A 125A

Frequency 50/60 Hz

Rated operating current [Ie]

AC21A 690Vac 40A 80A 125A

AC22A 690Vac 32A 80A 125A

AC23A 3ph-3poles

230V 32A 75A 125A

400/500V 32A 67A 125/100A

690V 20A 32A 80A

Rated breaking capacity (cosϕ 0.45) 400V 256A 536A 1000A (cosϕ 0.35)

Conditional rated short circuit 10kA 10.5kA

Fuse ratings gG 690V 40A 63A 125A

Connectable sectionflex cable 1.5 - 10 mm² 6 - 25 mm² 10-70 mm²

rigid cable 1.5-16 mm² / 12-6 AWG 10-35 mm² / 10-2 AWG 10-70 mm²

General use UL 508 600Vac 40A 80A -

Terminal protection class IP20 - (IP10 for SQ125)

Fixing system DIN-rail 50022-35 or with screws

Dimensions

Series A B C D E F G L

SQ032 45 52.6 22 60 12.5 13.5 60.3 80÷142 max

SQ063 52.5 72.5 43.5 82.5 17.5 23.5 57.8 112÷142 max

SQ125 65.2 92 51.2 102.2 22.5 16 64 127÷327 max

for series code

SQ032 012/0001 (○)

SQ063 042/0001 (○)

SQ125 231/0001

Door-interlock actuator

�Yellow front plate

�Red knob

�Locking knob (max 3 locks)

�Protection class EN60529: IP65

(○) UL50 type 1-4-4x

EN

ER

GY

& D

ATA

tra

nsm

issio

n

83

Annotations

Annotations:

Date post:	02-Apr-2016
Category:	Documents
Upload:	bernstein
View:	244 times
Download:	15 times

Handling system catalogue

Documents